Composite structural building panels and systems and method for erecting a structure using such panels

ABSTRACT

A composite panel includes a first skin including composite material, a second skin including drywall material, and a foam core therebetween. A plastic connector extends along side edges of the skins for connecting the panel to another composite panel including a mating connector. The connector includes a slot extending parallel to the side edges for receiving a pin therein, whereby the panel may be connected to another composite panel having a similar connector and slot. An I-beam is bonded between the skins in the cavity that includes a chase for receiving wiring or other utilities therein. A “U” shaped channel is also bonded between the upper edges of the first and second skins, thereby defining a recess between the upper edges for receiving a top plate to secure a roof structure to the panel.

[0001] This application is a continuation-in-part of co-pendingapplication Ser. No. 09/569,693, filed May 11, 2000, which is adivisional of application Ser. No. 09/169,059, filed Oct. 9, 1998, nowabandoned, the disclosures of which are expressly incorporated herein byreference.

FIELD OF THE INVENTION

[0002] The present invention relates generally to structural buildingcomponents and systems, and more particularly to composite structuralbuilding panels, connection systems and related components, and tosystems and methods for erecting structures including such panels.

BACKGROUND

[0003] Traditionally, housing or other building structures are erectedone component at a time, i.e., generally at the erection site. This mayinclude separately erecting or installing structural framework, shearsheathing, vapor barriers, protective exterior siding or finishes, andinterior finishes or paneling, such as gypsum board. The structuralframework may be erected from raw materials, e.g., lumber, and thenother components may be successively added to the framework until afinished structure is attained. The various components may be assembledtogether using a wide range of fasteners, such as, nails, nuts, bolts,screws, and/or other materials, such as gasketing, adhesives and thelike.

[0004] Because of the complexity of such structures, highly skilledtradesmen are required, and building them takes substantial time.Further, during construction, ancillary components, such as plumbing,mechanical and electrical systems, architectural features, such asroofmg and trim, interior features and the like, may be added tocomplete the structure. This may further increase labor and timedemands, and consequently result in relatively costly buildingstructures.

[0005] To reduce field costs and accelerate erection of buildingstructures, factory assembled components have been proposed. Forexample, prefabricated panels, generally made up of plywood applied overa expanded polystyrene (EPS) foam core, may be used to reduce fieldassembly time. In addition, subassemblies of framing or other structuralcomponents may be built in a factory or other offsite environment, wheremass production or improved efficiencies may be realized, as comparedwith field conditions. These components, however, may be bulky,resulting in dramatically increased shipping costs and/or requiring afactory in close proximity to the erection site.

[0006] Another problem with conventional building structures is thatthey often involve the use of wood products, particularly within theresidential industry, which are becoming increasingly scarce andexpensive. As an alternative, concrete and steel materials may be used,but these materials generally involve heavy equipment and special laborrequirements, which may dramatically increase erection time and cost.Further, steel and concrete materials may not adequately resistcorrosion and/or may involve complicated seismic load considerations.

[0007] More recently, plastic or composite materials, i.e., fiberreinforced plastic (“FRP”), have been considered for panel systems.These panels may simply substitute a composite material for one or moreelements of the panels, e.g., the outer skins, while using foam orhoneycomb core materials between the skins. Other composite panels havebeen suggested that use extruded or pultruded composite materials. Thesepanel systems, however, generally still require fasteners, e.g., screwsor bolts, in order to connect the panels to specially designed trimcomponents, beams, and the like. Thus, many of the components necessaryto assemble the panels and erect a building structure may be traditionalnon-composite materials, which may compromise the structural anddurability benefits obtained from the use of composite materials.

[0008] Other composite systems have suggested tongue and groove or “H”strip connectors between panels, but these systems may also requiremultiple fasteners to provide a structurally integral connection betweenthe panels. Alternatively, other composite systems may use resincatalystmixtures to bond panels together, but these systems may substantiallyincrease erection time, e.g., due to the curing time of panel joints,and/or may involve specially skilled field labor knowledgeable inworking with composite materials.

[0009] Accordingly, structural building components and systems that maybe assembled in a more efficient manner, and/or that may overcomeproblems associated with previous systems would be considered useful.

SUMMARY OF THE INVENTION

[0010] The present invention is directed to composite building panelsand related connection systems, and to methods for assembling and usingsuch panel systems to create building structures.

[0011] In accordance with one aspect of the present invention, acomposite panel for a structural building system is provided thatincludes a first skin formed from composite material, e.g., FRPincluding a phenolic resin, defining upper, lower, and side edges, and asecond skin defining upper, lower, and side edges spaced apart from thefirst skin, thereby defining a cavity between the first and secondskins. The second skin may be formed from composite material or fromdrywall material. A foam core is provided within the cavity, forexample, a polyisocyanurate foam injected between the first and secondskins to substantially fill the cavity.

[0012] A connector formed from plastic or composite material extendsalong a side edge, and preferably along each of the side edges, of thefirst and second skins for connecting the composite panel to anothercomposite panel including a mating connector. The connector may includean elongate slot extending generally parallel to the side edges forreceiving a pin therein, whereby the composite panel may be connected toanother composite panel having a similar connector and slot. Inaddition, the connector may include an inside face extending generallyparallel to a plane defined by the first and second skins, and the slotmay extend along the inside face between ends of the connector.Alternatively or in addition, the connector may include at least one ofa tongue and a groove extending along a length of the connector.

[0013] The composite panel may include one or more internal supportmembers, such as an I-beam. The I-beam, which may be formed from plasticor composite material, may space the first and second skins apart todefine the cavity. Alternatively or in addition, the connectors may bebonded between the first and second skins to space the first and secondskins apart and define the cavity. Optionally, the I-beam may include achase, e.g., within a tubular segment of the I-beam and extendingbetween its ends.

[0014] In addition, the composite panel may include a top plate, e.g., a“U” shaped channel, extending along the upper edges of the first andsecond skins. Preferably, the top plate is formed from plastic orcomposite material, and is bonded between the upper edges of the firstand second skins, thereby defining a recess between the upper edges.

[0015] In accordance with another aspect of the present invention, acomposite panel system for a building structure is provided thatincludes first and second composite panels. The first panel includes afirst skin including composite material, a second skin includingcomposite or drywall material, a foam core between the first and secondskins, and a first side edge. The second panel also includes a firstskin including composite material, a second skin including composite ordrywall material, a foam core between the first and second skins, and asecond side edge.

[0016] A connector is provided for securing the first and second membersrelative to one another along the first and second side edges. In oneembodiment, the connector may include a first connector member bonded tothe first edge of the first panel member, and a second connector memberbonded to the second edge of the second panel member. Each of the firstand second connector members may include a tongue and groove connectorincluding a slot extending along a length thereof. Preferably, the firstand second connector members are configured to interlock with oneanother to secure the first and second panel members to one another in aplanar configuration. More preferably, each of the first and secondconnector members includes a slot extending along a length thereof, theslots defining a passage when the first and second panel members areinterlocked. The composite panel system may include an elongate pininsertable into the passage to secure the first and second panel memberstogether.

[0017] Alternatively, the connector may also include a corner connectorconfigured to interlock with the first and second panel members tosecure the first and second panel members transversely with respect toone another. In a further alternative, the connector may include a “T”connector configured to interlock with the first and second panelmembers to secure the first and second panel members in a planarconfiguration. A third panel member may be provided that is configuredto interlock with the “T” connector to secure the third panel membertransversely with respect to the first and second panel members.

[0018] In addition, one or more “U” shaped base channel members may beprovided that include legs that are spaced for receiving lower edges ofthe first and second panel members therein.

[0019] In accordance with yet another aspect of the present invention, amethod is provided for manufacturing a composite panel that includesbonding a first web of an elongate support member, such as an I-beamformed from plastic, to a first skin, the first skin including compositematerial. A second web of the support member may be bonded to a secondskin including composite or drywall material. A connector may be bondedalong side edges of the first and second skins, and a foam core may beinjected into a cavity defined between the first and second skins. Inaddition, a top plate, e.g., a “U” shaped channel, may be bonded betweenupper edges of the first and second skins.

[0020] In accordance with still another aspect of the present invention,a method is provided for assembling a building structure from aplurality of composite panels including connectors extending along sideedges thereof. One or more lengths of “U” shaped base channel may besecured to a foundation, e.g., using fasteners and/or adhesives. A loweredge of a first composite panel may be placed into the base channel in asubstantially vertical orientation. A lower edge of a second compositepanel may be placed into the base channel adjacent the first panelmember. Connectors on the first and second composite panels may beinterlocked such that the first and second composite panels are disposedin a substantially planar configuration. The connectors of the first andsecond composite panels may be secured to one another, for example, byinserting a pin through mating slots in the connectors that define anenclosed passage when the connectors are interlocked. The first andsecond panels to the base channel, for example, by fasteners and/oradhesives, either before or after interlocking and/or securing the firstand second panels together.

[0021] Optionally, the first and second composite panels may include “U”shaped channels between upper edges thereof A top plate may be securedwithin the channels, and a roof structure may be secured to the topplate.

[0022] In addition, the first composite panel may include an internalchase disposed therein, and a utility accessory may be directed alongthe chase into the first composite panel. For example, a wire may beinserted into the chase, an opening may be created in a surface of thefirst composite panel to access the wire within the chase, and anelectrical box may be secured to the surface over the opening.

[0023] Other objects and features of the present invention will becomeapparent from consideration of the following description taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024]FIGS. 1A and 1B are front and top views, respectively, of acomposite panel, in accordance with the present invention.

[0025]FIG. 2 is an exploded perspective view of the composite panel ofFIGS. 1A and 1B.

[0026]FIG. 3 is a cross-sectional detail showing attachment of a topplate within a top channel of a composite panel.

[0027]FIG. 4 is a cross-sectional detail showing attachment of acomposite panel to a foundation of a building structure.

[0028] FIGS. 5A-5D are cross-sections, showing connectors and methodsfor connecting adjacent composite panels.

[0029]FIG. 6 is a partially exploded perspective view of a plurality ofcomposite panels arranged to provide a building structure.

[0030]FIG. 7 is a perspective detail showing installation of electricutility accessories to erected composite panels.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] Turning to the drawings, FIGS. 1A, 1B, and 2 show a preferredembodiment of a composite panel 10, in accordance with the presentinvention. Generally, the panel 10 includes a first or outer skin 12defining an upper edge 14, a lower edge 16, and side edges 18. Inaddition, the panel 10 includes a second or inner skin 22 also definingan upper edge 24, a lower edge 26, and side edges 28. The first andsecond skins 12, 22 are spaced apart a predetermined distance, forexample, by one or more connectors 32 and/or one or more internal I-beamsupports 40, thereby defining a cavity 30 therebetween. The cavity 30may be filled with an insulating material, e.g., a foam, such aspolyisocyanurate, as described further below.

[0032] A connector 32 may be provided along one set of side edges 18,28, and preferably on both opposing side edges 18, 28. Each connector 32generally includes a tongue 34 and a complementary shaped groove 36extending along a length of the connector 32. Preferably, the tongue 34and groove 36 are disposed adjacent one another to generally define an“L” shape. The tongue 34 and groove 36 define an inside face 37 betweenthem having a slot 38 therein. Preferably, the inside face 37 extendssubstantially parallel to a plane defined by the first and second skins12, 22 of the connector 18 to facilitate interlocking connectors onadjacent panels, e.g., in a generally planar orientation, as explainedfurther below. The slot 38 preferably has a generally hemisphericalcross-section, although other alternative cross-sections may also beprovided, such as square, rectangular or other radially symmetricalshapes. Further, the slot 38 may be provided at a midpoint of the insideface 37, or in some other symmetrical manner.

[0033] As shown in FIGS. 5A-5D, the connector 32 may be configured toslidably interlock with a similar connector 32′ provided on anotherpanel 10′ or a connector element 132, 232, 332 for special connectors110, 210, 310, as described further below. For example, as best seen inFIG. 5A, when connectors 32, 32′ are interlocked, the tongues 34, 34′may be received in the mating grooves 36′, 36. As this occurs, the slots38, 38′ become aligned with one another to together define a passage 39.The passage 39 may extend generally parallel to side edges of the panels10, 10′, e.g., between their upper and lower edges. Alternatively, otherconnectors, such as “H” strips or other tongue and groove connectors(not shown), may be used instead of the generally “L” shaped connectors32.

[0034] Returning to FIGS. 1A, 1B, and 2, the panel 10 may include one ormore internal support members, such as I-beams 40, between the first andsecond skins 12, 22. Each I-beam 40 may have a cross-section includingopposing webs 42, 44 spaced apart by a leg 46, preferably such that theI-beam 40 has a height similar to the spacing between the first andsecond skins 12, 22. In addition, the I-beam(s) 40 may include a tubularsegment 48 formed in the leg 46, e.g., defining a utility chase.Alternatively or in addition, the panel 10 may include one or moretubular elements 52 (shown in FIG. 1B) within the cavity 30 separatefrom the I-beam(s) 40 for providing utility chases.

[0035] Each I-beam 40 may have a length similar to or slightly less thana height of the first and second skins 12, 22. Preferably, each I-beam40 extends substantially parallel to the side edges 18, 28, e.g., fromthe lower edges 16, 26 towards the upper edges 14, 24 of the first andsecond skins 12, 22. Thus, the I-beam(s) 40 may divide the cavity 30into subcavities 30a-30c (shown in FIG. 1B), each of which may be filledwith an insulating material.

[0036] Optionally, the upper edges 18, 28 and/or lower edges 16, 26 maybe sealed or otherwise faced off, e.g., to substantially seal the cavity30. For example, as shown in FIGS. 2 and 3, a top plate 60 may beprovided between the upper edges 18, 28 of the first and second skins12, 22 to face off . Preferably, the top plate 60 includes opposing legs64 connected by a base 66, thereby defining a “U” shaped channel 62.Preferably, the top plate 60 is disposed such that the channel 62 isdisposed away from the lower edges 16, 26 and more preferably such thatthe legs 64 of the top plate 60 are substantially flush with the upperedges 18, 28 of the skins 12, 22, as best seen in FIG. 3.

[0037] Returning to FIG. 2, the first skin 12 may be formed from plasticor composite material. “Composite” material as used herein generallyrefers to material that is formed from fiber materials impregnated in aresin. The term “fiber-reinforced plastic” or “FRP” may be usedinterchangeably herein with the term “composite” to refer to the sameclass of materials. Generally, the fiber material may be formed fromlong fiber strands, e.g., woven cloth mat or other configurations offilaments, made from generally inert materials, such as glass, carbon,graphite, boron, quartz and the like.

[0038] The resin may be selected from a number of thermoset plastics,such as polyvinyl chloride (PVC) or PVC derivatives, and/orthermoplastic materials, such as phenolics, polyesters, vinylesters,polypropylenes, epoxies, and polycarbonates. Ultraviolet inhibitors maybe added, if desired, to all or selected components, such as exteriorskins, to protect the components from damage due to exposure tosunlight. Phenolic resins may be preferred as they have a higherresistance to fire as compared to other resins, i.e., they haverelatively low coefficients of flame spread and smoke generation duringcombustion, and may be formulated such that they will not supportsubstantial combustion at all. Phenolic resins also do not includestyrenes, which may provide an improved environment during manufacturingand/or pre-assembly of the panels over other resins. Phenolic resins,however, may be corrosive and consequently may require specialprotection of manufacturing equipment and/or panel components duringmanufacturing. In a preferred form of the present invention, fiberglassis impregnated within a phenolic resin in proportions of about 15-60%fiberglass by volume, and more preferably about 25-35% fiberglass, toprovide a preferred composite material.

[0039] The second skin 22 may be formed from a variety of materials,such as plastic or composite material, similar to the first skin 12.Preferably, however, the second skin 22 includes a panel of drywallmaterial, e.g., paper-covered gypsum board, such that the second skin 22may provide a rough finish for an interior surface of a structure (notshown), as explained further below.

[0040] The connector(s) 32 may be formed from plastic or compositematerial, similar to the first and second skins 12, 22. Because theconnector(s) 32 may not be exposed upon assembly of a building structureusing the panel 10, the connector(s) 32 may be formed from plastic, suchas polyvinyl chloride (PVC), which may be extruded or otherwise formedrelatively easily and inexpensively, as compared to composite materials.Similarly, the I-beam(s) 40 and/or top plate 60 may be formed fromplastic or composite material, and preferably from plastic, such as PVC.Alternatively, if additional fire resistance is desired, theconnector(s) 32, I-beam(s) 40, and/or top plate 60 may be formed fromphenolic resin FRP.

[0041] To manufacture a panel in accordance with the present invention,the first skin 12 may initially be manufactured from composite material,e.g., including filaments made from generally inert materialsimpregnated in a thermoset plastic resin or a thermoplastic resin, asdescribed above. The first skin 12 (and the second skin 22, if formedfrom composite material) may be formed by a pultrusion process duringwhich fiber material is directed through a resin bath. The resultingcomposite is pulled through a die where it is formed into a desiredshape, and cured. Similarly, composite accessories, e.g., connectorsand/or I-beams, may also be formed using a pultrusion process. Such aprocess may allow the components to be manufactured on a continuousbasis using a panel machine or impregnator, known to those skilled inthe art. The composite material may be fed continuously through the die,and then cut into predetermined lengths once cured. Because of thepartial automation provided by pultrusion processes, high volume, highefficiency manufacturing may be obtained.

[0042] Alternatively, “open mold” wet lay-up methods may be used duringwhich one or more of the components may be manufactured individually.This may reduce output volume, but may allow special textures, such asan architectural finish, e.g., a stone or brick pattern, a stuccopattern, a tile pattern, a wooden panel pattern, and the like, to beincorporated into finished components, such as an outer skin. Forexample, sheet molding compound or “pre-preg” may be used, in whichresin is pre-applied to the fiber reinforcement and provided in anuncured sheet form. The sheet may be placed in a mold having a surfacefinish thereon, and heat and/or pressure may be applied to cure thematerial and mold the surface finish directly into the sheet.

[0043] No matter what method is used, the first skin(s) 12 (andoptionally second skin 22) may be formed into any desired size, i.e.,height and width, and or cut into desired sizes from production-sizeskins. Preferably, the skin(s) 12 may be formed into standard widths,e.g., seventy two inches (72 in.), that provide desired structuralcharacteristics and/or handling weights for the resulting panels.

[0044] The first skin 12 may be positioned in a jig (not shown) with aninside surface facing upwardly, and then any desired accessories may bebonded to the inside surface of the first skin 12, e.g., using anadhesive, such as a two part polyurethane or epoxy adhesive. Forexample, connectors 32 may be aligned such that they overlap the sideedges 18, i.e., providing a lapped joint, and bonded to the first skin12. Similarly, any internal I-beams 40 may be positioned substantiallyparallel to the side edges 18, e.g., distributed evenly between the sideedges 18 and bonded to the inside surface of the first skin 12. In apreferred embodiment, the connectors 32 and I-beams 40 are each bondedsuch that one end is substantially flush with the lower edge 16 and theother end is below the upper edge 14, as may be seen in FIG. 1A. Topplate 60 may also be positioned along the upper edge 18 and bonded tothe inside of the first skin 12. Preferably, the top plate 60 ispositioned adjacent the ends of the connectors 32 and/or I-beams 40 suchthat the top plate 60 is substantially flush with the upper edge 18.

[0045] The second skin 22 may then be overlaid and bonded to theconnectors 32, I-beams 40, and/or top plate 60. The second skin 22preferably has dimensions similar to the first skin 12, such that theskins 12, 22 may be aligned with one other to provide a substantiallysquared panel 10. In a preferred embodiment, the second skin 22 is aprovided from a drywall material, although the second skin 22 may alsobe composite. For drywall material, an adhesive, such as a two partpolyurethane adhesive or epoxy adhesive, may be used to bond the drywallmaterial directly to the connectors 32 and/or I-beams 40. Alternatively,an intermediate layer of plastic or composite (not shown) may beoverlaid and bonded to the connectors 32 and/or I-beams 40, and the skinof drywall material may be bonded to the intermediate layer. It will beappreciated that the order of the steps described above is notimportant, and that the panel 10 may be assembled using any sequence ofsteps that result in the assembled configuration of the panel 10 shownin FIGS. 1A and 1B.

[0046] With the skins 12, 22 bonded to the connectors 32, a cavity 30 isdefined that may be filled with an insulating material, for example, toprovide increased insulation values, security, sound absorption, fireresistance and/or structural strength. Preferably, insulation materialmay be a foam that is injected or otherwise introduced into the interiorpanel spaces after assembly, for example, foam polyurethane, such aspolyisocyanurate. Foam material may be preferred, because it may expandafter introduction into the cavity 30, thereby minimizing the risk ofcreating voids within the panel 10. Alternatively, other flowablematerials may be used to fill the cavity 30, such as light-weightconcrete. If the cavity 30 is divided into subcavities, e.g., byinternal supports, each subcavity may be independently filled with foamor other insulation, or the internal supports may include holes toaccommodate the insulation flowing between the subcavities. In a furtheralternative, the cavity 30 may remain empty, and recycled fillermaterials and/or naturally-occurring filler materials available at ornear the erection site may be used to fill the cavity immediately beforeerection. In yet a further alternative, insulation, such as conventionalfiberglass blanket insulation, may be placed between the connectors 32and/or I-beams 40 before overlying the second skin 22.

[0047] Other accessories for the panel system, such as the specialconnectors, channels, and/or trim, may also be manufactured, forexample, using a pultrusion method or using an extrusion process, asdescribed above. Although an extrusion process may be performed onphenolic resin composites, PVC or PVC derivative materials may beextruded more easily, and may be preferred for accessory components thatare not likely to be exposed upon erection of the structure. For exposedaccessories, such as the comer connector 132, spacer connector 232, and“T” connector 332 described below, a phenolic resin composite ispreferred, and the accessories may be manufactured using a pultrusion orextrusion process.

[0048] For example, as shown in FIG. 5B, a comer connector 132 may beprovided for connecting panels 10, 10′ in a transverse orientation,e.g., ninety degrees from one another. The comer connector 132 mayinclude an elongate generally square shaped column portion 134 fromwhich a pair of panel connectors 136, 136′ extend. Preferably, the panelconnectors 136, 136′ are integrally molded to the column portion 134,e.g., from a phenolic resin. Preferably, the panel connectors 136, 136′are oriented substantially perpendicularly to one another to generallydefine an “L” shape. The panel connectors 136, 136′ generally includetongues 138 and grooves 140 adjacent to one another, thereby defining aninside surface 142 having a generally hemispherical slot 144 therein,similar to the connectors 32 described above.

[0049] Turning to FIG. 5C, a spacer connector 232 is shown that may beused to connect two panels 10, 10′ in a substantially planarconfiguration. Similar to the corner connector 132, the space connector232 includes a pair of panel connectors 236, 236.′ The panel connectors236, 236′ include tongues 238 and grooves 240 adjacent to one another,thereby defining an inside surface 242 having a generally hemisphericalslot 244 therein, similar to the comer connector 132. Preferably, thepanel connectors 236, 236′ are oriented away from one another and spacedapart a predetermined distance. Thus, the spacer connector 232 may beused to connect adjacent panels 10, 10′ when the distance between thepanels 10, 10′ is smaller than practicable to manufacture a relativelynarrow panel.

[0050] Turning to FIG. 5D, a generally “T” shaped connector 332 is shownthat includes three panel connectors 336, 336′, 336. “Preferably, eachof the panel connectors 336, 336′, 336” include tongues 338 and grooves340 adjacent to one another, thereby defining an inside surface 242having a generally hemispherical slot 244 therein, similar to theconnectors 32, 132 described above. A “T” shaped connector mayfacilitate connection between outer wall panels 10, 10′ of a buildingstructure and an interior wall panel 10″ abutting against the outer wallpanels 10, 10.′ Alternatively, a “U” channel (not shown) may be used tosecure intersecting walls, for example, where an interior wall may beconnected to an exterior wall of a structure.

[0051] Turning to FIG. 6, a set of panels and accessories may bemanufactured, e.g., using the methods described above, to provide asystem for erecting a building structure. The set of panels may includea plurality of standard panels and/or one or more custom panels suchthat, when they are properly assembled, the building structure may beerected. For example, a set of standard width wall panels 410, 412, 414may be provided, as shown, if the configuration of the structure allows.Alternatively, custom width panels (not shown) and/or spacer connectors232 (not shown in FIG. 6) may be used to complete dimensions that do notaccommodate use of standard width panels. Architectural features, suchas window or door openings (not shown), may be cut into individualpanels during manufacturing, or may be field cut during erection.

[0052] Optionally, composite panels may be manufactured for use asinternal walls, such as the representative panel 416 shown.Alternatively, internal walls may be provided from conventionalmaterials. Similarly, composite panels may be provided for a roof of thestructure, such as the representative panels 418. Alternatively, a roofmay be fabricated from conventional materials that may be connected tocomposite wall panels, as explained further below.

[0053] The composite panels are preferably manufactured and assembled ata manufacturing site where efficiencies may be realized and/or laborcosts controlled more effectively. Thus, upon delivery to an erectionsite, no assembling individual panels may be required. Alternatively, ifshipping volume is an important consideration, the panel components maybe shipped unassembled, and assembled and bonded into panels at or nearthe erection site.

[0054] With reference to FIGS. 3, 4, and 6, a method for erecting abuilding structure, such as the structure 400 shown in FIG. 6, using aplurality of panels in accordance with the present invention, is nowdescribed. Initially, a foundation may be created in a conventionalmanner, e.g., a raised foundation and/or a concrete slab, such as thefoundation 90 shown in FIG. 4. Base channel 70 may be secured to thefoundation 90, for example, anchored using fasteners 72, such as boltsor screws, and/or using adhesives. Preferably, the base channel 70 is a“U” shaped channel including a pair of opposing legs 74 connected by abase 76, thereby defining a channel 78 having a size to fit panelstherein. The base channel 70 may be pultruded or extruded from plasticor composite material, as described above. Preferably, the base channel70 is extruded from PVC, as it may not be exposed once the buildingstructure is complete. The base channel 70 may be cut to length and laidout to define a footprint (shown partially in FIG. 6) of the structurebefore installing the panels or as wall segments are assembled.

[0055] As shown in FIG. 4, a lower edge of a first panel 10 may beplaced into the base channel 70 in a substantially vertical orientation.Optionally, the first panel 10 may be secured to the base channel 70,for example, by drilling or screwing fasteners, e.g., screws or rivets,through the legs 74 into the first and/or second skins 12, 22. Thefasteners may be spaced apart along the base channel 70 a predetermineddistance to ensure structural engagement between the panel 10 and thebase channel 70.

[0056] A lower edge of a second panel (not shown) may be placed into thebase channel 70 adjacent the first panel member 10 and then slid towardsthe first panel 10. As shown in FIG. 5A, connectors 32, 32′(also notshown) on the first panel 10 and the second panel 10′ may interlock suchthat the first and second panels 10, 10′ are disposed in a substantiallyplanar configuration. Preferably, once the connectors 32, 32′ are fullyinterlocked, the slots 38, 38′ together define an passage 39. A pin,such as an elongate rod or tube (not shown), e.g., formed from metal,wood, or composite material, may be inserted into the passage 39. Thepin may substantially lock the connectors 32, 32′ together, andconsequently secure the panels 10, 10′ together. The second panel may besecured to the base channel 70, for example, using fasteners, similar tothe first panel 10. It will be appreciated that the fasteners may beused to secure the panels to the base channel before or after insertingany pins to secure the panels to one another.

[0057] Generally, with particular reference to FIG. 6, erection maybegin in a comer of the structure, for example, at the comer labeled“A.” Initially, a comer connector 132 may be placed into one end of abase channel 70, and adjacent panels 412, 414, etc. may be successivelyinterlocked with the comer connector 132 and with one another. Anyspacer connectors or “T” connectors (not shown) may be interlocked asappropriate until the next comer connector 132 is installed. Each of thewalls may be erected in a similar manner, as will be appreciated bythose skilled in the art. Pins (not shown) may be used to secured thepanels and/or connectors to one another, and fasteners (not shown) maybe used to secure the panels and/or connectors to the base channel 70.If desired, trim (not shown) may be applied along the panels to coverthe base channel 70 and/or any fasteners, which may be formed fromconventional materials, plastic, or composite materials.

[0058] Turning to FIG. 3, any or all of the wall panels described above,represented by panel 10, may include a top channel 60 bonded between thefirst and second skins 12, 22. A top plate 82 may be inserted and/ormounted into the channel 62 defined by the top channel 60, e.g., along abetween a plurality of adjacent panels (not shown). The top plate 82 maybe an interface for connecting a roof structure to the wall panels, andmay be formed from conventional materials, e.g., lumber or steel, orfrom plastic or composite materials. Preferably, the top plate 82 is aconventional structural element, such as a piece of lumber (e.g., a2″×4″), that is secured into the channel 62 using fasteners 80, such asnails, screws, bolts, and the like. The top plate 82 may include a metalsheet 84 secured along the top plate 82 to which trusses or other roofstructure components (not shown) may be secured.

[0059] A roof structure (not shown) may be secured to the trusses thatmay be provided from conventional materials. Alternatively, as shown inFIG. 6, a roof including composite panels 418 may be secured to the topof the wall panels 412, 414. Exemplary connectors for securing compositeroof panels to composite wall panels are disclosed in the parentapplications incorporated above.

[0060] Turning to FIG. 7, any of the wall panels, such as therepresentative panel 10, may include internal support members, such asI-beams 40 including tubular segments 48 providing utility chases.Alternatively, separate tubular chases (not shown) may be providedwithin the panels. Preferably, the chases 48 are disposed verticallywithin the panel 10, thereby providing a simplified method forinstalling utility accessories, such as electrical boxes 86. When alocation of an electrical box 86 is identified, an electrical cable orwire 88 may be directed into the nearest I-beam tubular segment 48 ofpanel 10. This may require cutting an opening in the top channel 60 ofthe panel 10. An opening may be created, e.g., in an inner skin 12 ofthe panel 10 to access the tubular segment 48, and pull the wire 88 fromwithin the chase.

[0061] The electrical box 86 may be secured to the to the inner skin 12of the panel 10, and an outlet, switch, and the like (not shown) may becoupled to the wire 88 and mounted to the electrical box 86. If theinner skin 12 is provided from composite material, the electrical boxmay also be provided from plastic or composite material and bonded tothe inner skin 12. Alternatively, the electrical box 86 may be securedto the inner skin 12 using fasteners, such as screws, nails, and thelike. Although attic access is shown for introducing wires 86 into thechases 48, a crawl space, if the structure includes a raised foundation(not shown), may be used to access the chases 48 from below. Similarly,other utilities, such as plumbing and heating accessories, may beintroduced into walls using such chases, in addition to or instead ofelectrical utilities, although the size of the chase required may varydepending upon the accessory being introduced.

[0062] A significant advantage of composite panels, as compared to woodor other traditional materials, is that the composition of compositematerials may be modified in a predetermined manner to optimize thestructural characteristics of components or systems formed using them.For example, the fiber reinforcement content of the material may beincreased to generally increase the strength of the resulting structure,particular arrangements of fibers may be selected to provide selectedstructural properties, and the like. In addition, the spacing andconstruction of internal support members may be selected to providedesired structural properties.

[0063] In addition, an exterior skin of composite material may bemanufactured with a desired architectural finish, thereby reducingexterior finish work on the exterior of the structure. Similarly,composite panels including drywall inner skins may provide a roughfinish for the interior of the structure, only requiring painting orother finishes.

[0064] Another advantage of connection systems in accordance with thepresent invention is that special tools and fasteners may be eliminated.Although fasteners may be required to secure the wall panels to basechannel or to connect a roof structure to wall panels, the connectors ofthe present system may only require a single pin to assemble and secureadjacent wall panels. Thus, a substantial volume of hardware generallyrequired for erecting building structures may be eliminated.

[0065] While the invention is susceptible to various modifications, andalternative forms, specific examples thereof have been shown in thedrawings and are herein described in detail. It should be understood,however, that the invention is not to be limited to the particular formsor methods disclosed, but to the contrary, the invention is to cover allmodifications, equivalents and alternatives falling within the spiritand scope of the appended claims.

What is claimed is:
 1. A composite panel for a structural buildingsystem, comprising: a first skin formed from composite material definingupper, lower, and side edges; an elongate I-beam comprising plastic, theI-beam bonded to the first skin and extending at least partially betweenthe upper and lower edges; a second skin comprising drywall materialdefining upper, lower, and side edges, the second skin bonded to theI-beam such that the first and second skins define a cavitytherebetween; a foam core within the cavity; and a connector comprisingplastic extending along the side edges of the first and second skinsfore connecting the composite panel to another composite panel includinga mating connector.
 2. The composite panel of claim 1, wherein the firstskin comprises a fiberreinforced plastic comprising a phenolic resin. 3.The composite panel of claim 1, wherein the I-beam comprises a chasetherein extending between its ends.
 4. The composite panel of claim 1,wherein the I-beam comprises a leg and a web on each end of the leg, theleg defining a width of the cavity between the first and second skins,the first and second skins being bonded to respective webs on oppositeends of the leg.
 5. The composite panel of claim 1, wherein the secondskin comprises gypsum board.
 6. The composite panel of claim 1, whereinthe foam core comprises polyisocyanurate foam injected between the firstand second skins to substantially fill the cavity.
 7. The compositepanel of claim 1, wherein the connector includes an elongate slotextending generally parallel to the first edge for receiving a pintherein, whereby the composite panel may be connected to anothercomposite panel having a similar connector and slot.
 8. The compositepanel of claim 7, wherein the connector comprises an inside faceextending generally parallel to a plane defined by the first and secondskins, and wherein the slot extends along the inside face between endsof the connector.
 9. The composite panel of claim 1, wherein theconnector comprises at least one of a tongue and a groove extendingalong a length of the connector.
 10. The composite panel of claim 1,wherein the connector is bonded to the side edges between the first andsecond skins.
 11. The composite panel of claim 1, wherein the connectorcomprises first and second connectors comprising plastic extending alongopposite side edges at least partially defined by the first and secondskins.
 12. The composite panel of claim 1, further comprising a topplate extending between the upper edges of the first and second skins.13. The composite panel of claim 12, wherein the top plate comprisespolyvinyl chloride, and wherein the top plate is bonded between theupper edges of the first and second skins.
 14. The composite panel ofclaim 12, wherein the top plate comprises a “U” channel inserted betweenthe upper edges of the first and second skins, thereby defining a recessbetween the upper edges.
 15. The composite panel of claim 1, wherein thefirst skin comprises an exterior surface having a predeterminedarchitectural finish molded directly into the composite material.
 16. Acomposite panel system for a building structure, comprising: a firstpanel member comprising a first skin including composite material, asecond skin including drywall material, and a foam core between thefirst and second skins, the first panel member comprising a first sideedge; a second panel member comprising a first skin including compositematerial, a second skin including drywall material, and a foam corebetween the first and second skins, the second member comprising asecond side edge; and a connector for securing the first and secondmembers relative to one another along the first and second side edges.17. The composite panel system of claim 16, wherein the connectorcomprises a first connector member bonded to the first edge of the firstpanel member, and a second connector member bonded to the second edge ofthe second panel member.
 18. The composite panel system of claim 17,wherein each of the first and second connector members comprises atongue and groove connector including a slot extending along a lengththereof.
 19. The composite panel system of claim 17, wherein the firstand second connector members are configured to interlock with oneanother to secure the first and second panel members to one another in aplanar configuration.
 20. The composite panel system of claim 19,wherein each of the first and second connector members comprises a slotextending along a length thereof, the slots defining a passage when thefirst and second panel members are interlocked, and wherein thecomposite panel system further comprises an elongate pin insertable intothe passage to secure the first and second panel members together. 21.The composite panel system of claim 17, wherein the connector furthercomprises a comer connector configured to interlock with the first andsecond panel members to secure the first and second panel memberstransversely with respect to one another.
 22. The composite panel systemof claim 17, wherein the connector further comprises a “T” connectorconfigured to interlock with the first and second panel members tosecure the first and second panel members in a planar configuration, andwherein the composite panel system comprises a third panel memberconfigured to interlock with the “T” connector to secure the third panelmember transversely with respect to the first and second panel members.23. The composite panel system of claim 16, further comprising a “U”shaped base channel member, legs of the base channel spaced forreceiving lower edges of the first and second panel members therein. 24.The composite panel system of claim 16, wherein the connector comprisesone of plastic and composite material.
 25. A method for manufacturing acomposite panel, comprising: bonding a first web of an elongate supportmember to a first skin, the first skin comprising composite material,the support member comprising plastic; bonding a second web of thesupport member to a second skin comprising drywall material; bonding aconnector along side edges of the first and second skins; and injectinga foam core into a cavity defined between the first and second skins.26. The method of claim 25, further comprising bonding a top platebetween upper edges of the first and second skins.
 27. The method ofclaim 25, comprising the additional step of molding an architecturalfinish directly into an outer surface of the first skin.
 28. A methodfor assembling a building structure from a plurality of composite panelscomprising connectors extending along side edges thereof, the methodcomprising: securing “U” shaped base channel to a foundation; placing alower edge of a first composite panel into the base channel in asubstantially vertical orientation; placing a lower edge of a secondcomposite panel into the base channel adjacent the first panel member;interlocking connectors on the first and second composite panels suchthat the first and second composite panels are disposed in asubstantially planar configuration; securing the first and second panelsto the base channel; and securing the connectors of the first and secondcomposite panels to one another.
 29. The method of claim 28, wherein theconnectors comprise slots that define an enclosed passage when theconnectors are interlocked, and wherein the step of securing theconnectors comprises inserting a pin into the passage.
 30. The method ofclaim 28, wherein the first and second composite panels comprise “U”shaped channels between upper edges thereof, and wherein the methodfurther comprises: securing a top plate within the channels; andsecuring a roof structure to the top plate.
 31. The method of claim 28,wherein the first composite panel comprises an internal chase disposedvertically therein, and wherein the method further comprises directing autility accessory along the chase.
 32. The method of claim 31, whereinthe utility accessory comprises one or more electrical wires, andwherein the method further comprises: creating an opening in a surfaceof the first composite panel to access the wire within the chase; andsecuring an electrical box to the surface over the opening.